Casting form



March 10, 1953 PETERSON 2,630,614

CASTING FORM Filed May 4, 1951 2 SHEETSSHEET 1 March 10, 1953 L. L. PETERSON CASTING FORM 2 SHEETS-SHEET 2 Filed May 4, 1951 RWLLEM E EI L ME

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Patented Mar. 10, 1953 UNITED STATES ATENT OFFICE 6 Claims.

The present invention relates to molds adapted to receive amorphous or fiowable casting material and to constrain the material during a hardening period and more particularly to such a mold especially suited to the formation of hollow bodies of slab or wafer-like shape.

The difliculties incident to the casting of hollow members of cement, plastic or other material by a single operation are well known. Excessively complex molds are usually required for such purposes and substantial difliculties encountered in separating the cast members from the molds in which they are formed. Although molds intended for use in the formation of hollow bodied members have been known; the difliculties incident to their employment have been such that commercial production of hollow bodied members has involved the casting of fragmentary portions thereof of convenient shape and subsequently assembling the portions into a completed unit.

Recent developments in the prefabrication of buildings has resulted in the discovery by the applicant of a building slab of specialized cnfiguration having construction advantages. The slabs have voids therein for insulation and weight reducing purposes and are characterized by an assembly convenience enabling the speedy and dependable association of a plurality of such slabs in building construction. The molding or casting of slabs of the type to which reference has been made characterizes the casting difficulties which the present invention has successfully overcome. The slab, to which reference herein is subsequently made in greater particularity, is described for illustrative convenience and it is evident that the mold of the present invention is not limited to the production of such slabs but may successfully be employed in the production of cast articles of various configurations having voids extended inwardly from outer surfaces thereof.

An object of the present invention is to provide an improved mold for casting members of various shapes and sizes particularly adapted to the formation of voids or openings in such members.

Another object is to provide a mold which makes provision for the dependable location of a plurality of removable cores therein.

Another object is to provide an improved collapsible core for matrixes which is conveniently assembled for casting operations and expeditiously collapsed for removal from formed articles.

Another object is to provide an improved combination of matrix and core therefor accommd dating adjustable arrangement of the cores in the form to suit specialized production requirements.

Other objects are to provide improved elements and arrangements thereof in a device of the character and for the purposes set forth that is economical, durable, and possesses improved operating characteristics.

Further objects and advantages will become apparent in the subsequent description in the specification.

Referring to the drawings:

Fig. 1 is a perspective view of a slab formed from concrete or other flowable material by use of the mold of the present invention.

Fig. 2 is a perspective View of the matrix of the instant invention at a stage of its assembly.

Fig. 3 is a perspective of a completely assembled matrix and cores constituting a mold embodying the principles of the invention herein described.

Fig. 4. is a perspective of the mold showing a modified association of the parts thereof, as for the reception of an auxiliary frame adapted to define a window opening or the like.

Fig. 5 is a transverse section through the mold, as taken along line 55 in Fig. 3.

Fig. 6 is a perspective view of one of a plurality of collapsible cores used in connection with the matrix for forming the hollowed or cored out portions of the slab shown in Fig. 1.

Fig. 7 is a perspective view of the end of the collapsible core, opposite to that viewed in Fig. 6.

Fig. 8 is a horizontal longitudina1 section through the collapsible core, foreshortened for illustrative convenience, taken along line 3-8 of Fig. 7.

Fig. 9 is a foreshortened vertical longitudinal section through the collapsible core, as viewed from line 99 of Fig. '7.

Referring in greater detail to the drawings:

The mold of the present invention is adapted to be used in the cast formation of a block or slab from amorphous or fiowable material by the constraining of such material to predetermined shape during a hardening period. Such a slab of concrete is indicated at H] in Fig. 1. The block is formed with a pair of spaced parallel panels ll of generally rectangular form interconnected by a central transverse rib l2 and a plurality of parallel longitudinal ribs IS. The spaces between the parallel ribs 13 and the panels ll provide pockets or voids [4 which reduce the weight of the block and provide insulating space and access between the panels, as for plumbing and wiring convenience in building construction.

The slab ii) is formed with parallel side edges 25 which are recessed at it to provide longitudinal grooves which are transversely generally of trapezoidal form. When panels of the character described are arranged in edge to edge rel tion with the grooves it in juxtaposition and vertically disposed, the grooves define vertical bores adapted to receive slab interlocking pillars of concrete and reinforcing steel. The remaining edges ll and it of the slab, nominally the top and bottom edges respectively, are in parallel relation with the pockets I l extending inwardly from these top and bottom edges and terminating slightly short of the center of the slab to provide the central rib l2 of the slab. A reinforcing rod l9 extends longitudinally through the rib l2 and projects beyond the confines of the slab into the grooves 56. The reinforcin rods of adjacent slabs in a building construction are hooked or twisted together to prevent separation of the slabs subsequent to which mortar such as concrete is poured therebetween to form the described interlocking pillars.

The mold of the present invention employs a matrix 25 which mounts a plurality of cores Zl subsequently more fully described. The matrix includes a base plate 22 which is shown in the drawings as square but which may be given any suitable form. The base plate is conveniently of flat sheet material such as steel plate and provides parallel side edges 23 and end edges An elongated strip 25 of predetermined thickness is welded, bolted, or otherwise affixed to the opposite end edges 2 of the base plate. Corner blocks 27 are secured to the ends of each of the strips 2% and extend upwardly therefrom predetermined equal distances and provide faces flush with the ends of the strip 26. The corner blocks are recessed inwardly at 23, as shown. A vertical bore 29 is formed through each of the corner blocks 2'? for purposes hereinafter more fully described. A plurality of intermediate blocks 3d are secured to each of the strips 25: in equally spaced relation therealong and extend upwardly therefrom to the plane of the upper extremities of the corner blocks 21.

The spaces across the upper portions of the corner blocks 2?, intermediate blocks iii and the blocks themselves are covered by a removable cover strip Iii of substantially the same dimensions as the strip 26 with bores formed through each cover strip in alignment with the bores 29. With a cover strip 3! overlaying each set of blocks 21 and 38 an attaching pin 33 is insertible through the bores 29 and The pins may take the form of suitable nuts and bolts or other structure adapted dependably to locate its associated members in place on the base plate. The pins 33 are preferably rigidly and releasably mounted in the base plate as by screw-threaded engagement in bores, not shown, formed therein and provided with nuts 34% which are screwthreadably tightened on the upper ends thereof. With the cover strips in place, their upper surfaces are in a common plane in spaced parallel relation to the upper surface of the base plate and spaced therefrom a distance equal to the thickness of the slab it to be molded thereby. Also, with the cover strip in place, the spaces between adjacent slabs, the strips 2%, and the cover strips 3! provide core openings 35 through opposite end walls of the matrix. The spaced parallel strips 26, blocks El and 36 extending upwardly therefrom, and the cover strips 3i are adapted to form portions of the top ll and bot- 4 tom edges 58 of the slab l0 when formed in the matrix.

Means are provided along the remaining opposite side edges 23 of the base plate 25 for forming the recessed side edges 55 of the slab it. These means include a pair of channel members 35 which are located on the base plate in spaced parallel relation. The channels 36 provide walls which face toward each other and legs 38 extending outwardly therefrom. In order to form. the trapezoidal recessed portion It in the side edges l5 of the slab Hi, a convex extension 3d of suitable shape is secured to the wall of each channel 35. The extension 39 and the spaced walls of the channel members 36 together form the recessed side edges iii of the slab. The channel members 36 are maintained in assembled relation on the base plate with the extensions 39 located in the recesses 28 of the corner blocks 2'1 by the attaching pins 33 extended downwardly through the openings in the blocks and strips 26 while passing also through bores formed vertically through the extensions 39 adjacent to opposite ends thereof. Other openings 33 are optionally formed horizontally through the channels 36 and extensions 39 substantially midway of their lengths for the support of the reinforcing rod IS therethrough.

In order to form the pockets or voids I l inwardly of the top H and bottom edges it of the slab ill, a plurality of cores 2.] are provided which are illustrated in Figs. 6 to 9, inclusively. The cores are slidably fitted to the core openings 35 and held therein by placement of the .cover strips 3i thereover, as shown in Figs. 3 and 4. of the cores 2| is made of sheet metal and is of hollow rectangular form. Each core is also constructed of four substantially identical reversed corner segments 5|. Each of the corner segments 5! is formed of three integral panels including a face panel 52, a side panel 53 and an inner end panel 54. The four corner segments iii are located in overlapping relation, as illustrated in Fig. '7 of the drawing. The corner sections overlap or are nested with corresponding face panels 52, side panels 53, and end panels of adjacent sections overlapping. The overlapping end panels provide a closed inner end for their respective cores. It will be noted that the transversely adjacent end panels horizontally overlap and the vertically adjacent end panels vertically overlap. Juxtapositioned horizontally elongated slots 55 are formed through overlapping portions of the horizontally adjacent end panels. Juxtapositioned vertically elongated slots 56 are formed through the overlapping portions of the vertically adjacent end panels 54. Bolts 5? are extended inwardly through the slots 55 and 5t and are provided with nuts 58 screwthreadably mounted thereon. The bolts are preferably welded to the outermost end panel through which they extend for convenience in tightening the nuts within the cores. It will be noted that by loosening the nuts on their bolts the overlapping end panels are telescopically adjustable to contract or exp-and the cores. Conversely, tightening the nuts on their bolts dependably locks the end panels and thus the corner segments at their inner ends in adjusted relation determining selected transverse dimensions.

The bolts 57 extending through the slots 55 and 563 maintain the overlapping ends of the corner segments only in selected relation. It is also desirable to maintain the corner segments of the opposite, or open, end of the cores in fixed relation whenever they are in use in a mold. This is accomplished by providing a chan nelled collar 63 for each of the cores 2!. Each collar 63 is constructed of a pair of nested frames, namely, an outer frame 64 and an inner frame 65 somewhat smaller than the outer frame. Each of the frames are of open rectangular form and of angular shape in cross section having rearwardly disposed flanges, as seen in Figs. 8 and 9. The frames 64 and 65 are concentrically nested and contacting portions thereof spot welded so that the flanges provide a rearwardly disposed channel 66. The collar 63 is of such a size that when the open end edges of the corner segments are inserted into the channel of a collar, the open end of the core is maintained in expanded condition fitted to the core receiving openings 555.

To reinforce each core longitudinally so that it will not buckle along its length when flowable material is poured into the matrix or amorphous material compacted therein, an elongated Z-strip 68 of sheet metal is secured to the inner face of each face panel 52 and extended longitudinally thereof. The Z-shape of the strips til impart a rigidity to the cores desirable in sustain ing loads imposed thereon intermediate the support offered by the interconnected end panels 54 and the collars 63.

In the construction of slabs of the form indicated at it! in Fig. l, the cores 21 are arranged in the matrix 20 in the manner illustrated in Fig. 3. This is conveniently accomplished by removing the cover strips 3| from the blocks 2'! and 30 and positioning the cores in the openings 35 between the blocks 21 and 3G. The cores are preferably arranged in parallel relation and located so that their inner ends are equally spaced and define therebetween a form for the reception of flowable material in the formation of a transverse rib l2 and reinforcing rod l9. When the cores are properly arranged, the cover strips 3| are arranged in overlaying relation thereto and rigidly mounted by the attaching pins 33.

It sometimes is desirable to provide a window or door opening through the slab it. Slabs of such formation are conveniently formed by ad-- justing the mold of the present invention, as shown in Fig. l. A frame it! of the size and shape of a desired opening in the slab is rested on the base plate 22 in any desired position. The cores 2i which are laterally adjacent to the frame it are positioned as described in Fig. 3 for the formation of a slab it of the type shown in Fig. l. The cores which are endwardly aligned with the frame l'fl are slid outwardly through the openings 35 until the inner ends thereof are substantially equally spaced from the frame it as adjacent inner ends of the adjacent cores are spaced when no frame is employed. A reinforcing rod, or rods of any desired configuration are arranged in the mold. A suitable generally U- shaped rod is indicated at H extended through the openings t3 and bent around the frame it. It is to be understood that the clamping of the cover strips 3| against the cores H by means of the attaching pins 33 serves dependably to secure the cores in position Whether fully inserted as shown in Fig. 3 or partially retracted in order to utilize an auxiliary frame to form window openings, door openings, and the like. previously indicated, the nuts 58 are tightened on the bolts 5? and the collars 63 slidably located on the outer ends of the cores preliminary to clamped positioning in the matrix so that the segments 5! thereof are dependably intercom nected and constrained to desired relation.

Operation The operation and utility of the mold of the present invention are believed to be apparent and are briefly summarized at this point. In order to form the slab it as illustrated in Fig. 1, the matrix 2%! is located in a horizontal position ad jacent to a convenient source of casting material. The cores 2| and the cover strips El are removed therefrom but the strips 26 and channel members 38 all constrained to the positions shown in Fig. 2 by the pins 33 which extend through the end blocks 2'1, extensions 39 mounted on the channel members 38, and the strips 26. While in this condition a quantity of fiowable or amorphous material, such as fluid cement, is poured onto the base plate covering it to a depth substantially equal to the thickness of the strips 26. With the cores adjusted to cross sectional dimensions. having a width equal to the distances between the adjacent blocks 2'5 and st and a thickness equal to the heights of the blocks 2'! and 30, they are positioned between the blocks with their closed ends inwardly extended and arranged in equally spaced relation, as illustrated in Fig. 3. The space is maintained between the inner ends of adjacent cores so that the central rib 12 of a completed slab I0 is formed therein. The reinforcing rod I8 is inserted through the openings d3 between the ends of the cores and extended outwardly beyond the confines of the mold. The cover strips 31 are thereafter laid over aligned sets of blocks 21 and 3!) with the attaching pins 33 extending upwardly through the openings 32 through the cover strips. The nuts 3 provide a quick means of lightening the cover strips down on the blocks and clamping the cores on the strip 26 in cantilever extension into the mold. With the mold members thus assembled an additional quantity of the flowable material is poured into the mold sufiicient to fill the mold flush with the upper surfaces of the channel members 36 and the cover strips 3!. The fiowable material is troweled smooth and permitted to set or harden.

After the fiowable material, such as cement, has hardened the cores iii are removed therefrom and the slab removed from the matrix 26. The cores 2! are easily removed from the pockets I l of the slab by inserting a long shank socket wrench, not shown, into each of the cores and loosening the nuts 5% on the bolts 5?. In order to collapse the cores 2i throughout their lengths, the channeled collars 63 are slid endwardly from their respective cores. With the inner and outer ends of the cores thus free, each core may be easily and conveniently collapsed by a simple shaking movement and endwardly withdrawn from their respective pockets id in collapsed condition.

The cover strips 3i may be removed prior to withdrawal of the cores 2| or retained in position to protect the newly formed slab during core withdrawal. Subsequent to removal of the cores, the attaching pins 33 are disconnected from the base plate 22, as by being screw-threadably dlsengaged therefrom, and the channel members 38 and the strips 26 and 3| with their interconnecting blocks 27 and 38 removed from the base plate and the formed slab. The production of a slab having a window or door opening therein, as illustrated in Fig. 4, is substantially similar to that described for the slab Ill shown in Fig. 1

and .in View of the prior discussion thereof is not described further at this point.

The cores 2| of the present invention are readily adjustable, conveniently assembled, depend ably locked in adjusted arrangement, and easily arranged in the openings 35 as described. The matrix 20 is speedily assembled, receives the cores 2 I in simple association, and the cores and matrix locked in casting arrangement by tightening the nuts 3%.

It will be apparent to anyone skilled in the art that the matrix and cores may be made of any desired size and suitable shape and that slabs of relative proportions other than shown may be constructed merely by permitting the extension of the channel members and/or the strips 25 and Bi passed the ends of their associated wall elements to define a smaller casting area.

Although the invention has been herein shown and described in what is conceived to be the I most practical and preferred embodiment, it is recognized that departures may be made therefrom Within the scope of the invention, which is not to be limited to the details disclosed her in but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and structures.

Having described my invention, what I claim as new and desire to secure by L tters Patent is:

1. In a casting form, the combin on of a base plate; wall members mounted on the plate defining a casting area thereon, one of said wall members comprising a base strip of pr determined thickness rigidly mounted on the base plate, a plura ty of blocks mounted on the strip in predetermined spaced relation, and a cover strip releasably mounted in overlaying relation to the blocks; an elongated transversely collapsible core fitted between the blocks of the wall and extended inwardly in substantially parallel relation to the base plate into the cas"'ng area providing an inner end in spaced on to all portions of the wall member; and means for tightening the cover strip down on the blocks and clamping the core against the base strip in cantilever extension into the casting area in spaced relation to the base plate.

2. In a casting form, the combination of a base plate; walls releasably mounted on the base plate defining a casting area thereon, one of said walls comprising a base strip of predetermined thickness mounted on the base plate, a plurality of blocks mounted on the strip in predetermined spaced relation, and a cover strip releasably mounted in overlaying relation to the blocks; elongated transversely collapsible cores fitted between the blocks of the wall and inwardly extended into the casting area providing inner ends within the walls and open outer ends, each core consisting of a plurality of elongated longitudinal segments transversely slidably associated for adjustment of the over-all transverse dimensions thereof having angularly related inner ends slidably overlapped, and releasable means interconnecting the slidably overlapped inner ends to constrain the segments in adjusted transversely slidable relation; and means for tightening the cover strip down on the blocks and clamping the core against the base strip in cantilever extension into the casting area in spaced relation to the base plate,

3. In a casting form, the combination of a base plate; walls mounted on the base plate defining a casting area thereon, one of said walls including a base strip of predetermined thickness rigidly mounted on the base plate, a plurality of blocks mounted on the strip in predetermined spaced relation, and a cover strip releasably mounted in overlaying relation on the blocks; elongated transversely collapsible cores of substantially rectangular longitudinal and transverse configuration fitted between the blocks of the wall, inwardly extended into the casting area, and providing closed inner ends within the walls and outwardly disposed open ends, each of the cores including two pairs of elongated segments of sheet material arranged in substantially parallel pairs and the segments of each pair being in substantially parallel relation, each segment having a pair of integral elongated longitudinal panels transversely in substantially right angular relation, the segments of each pair having adjacent panels arranged in transversely slidable overlapping relation and the corresponding segments of the pairs having adjacent panels arranged in transversely slidable overlapping relation, the segments having right angularly extended inner ends slidably overlapped and proling elongated juxtapcsitioned openings, bolts extended through the openings having tightening means disposed within the core accessible throu h the open end thereof, and a collar telescopically slidably mounted on the segments at the open end of the core constraining the segto predetermined overlapping relation and having an access opening therethrough; and means ior tightening the cover strip down on the blocks and clamping the core against the base strip in cantilever extension into the casting area in spaced relation to the base plate.

In a casting form the combination of a base plate; walls mounted on the base plate defining a casting area thereon, one of said walls comprising a base strip of predetermined thickness *igidly mounted on the base plate, a plurality of blocks mounted on the strip in predetermined spaced relation, and a cover strip releasably mounted in overlaying relation to the blocks; and elongated transversely collapsible cores of substantially rectangular longitudinal and transerse configuration fitted between the blocks of the wall, inwardly extended into the casting area,

clam ed cantilever extension in substantially parallel relation to the base plate by the cover strip; each of the cores including two pairs of longated segments of sheet material arranged in substantially parallel pairs and each pair consisting of substantially parallel segments, each segment including an elongated face panel longitudinally of the segment, an elongated side panel longitudinally of the segment transversely in substantially right angular relation to the face panel, and an end panel interconnecting corresponding ends of the face panel and the side panel in fixed angular relation, the face panels and the end panels respectively of the segments of each pair of segments slidably overlapping and the side panels and the end panels respectively of corresponding segments of the pairs slidably overlapping, the overlapping portions or" the end panels having juxtapositioned elongated openings formed therethrough, screw-threaded means mounted in the openings adapted to clamp their respective end members in adjusted overlapping relation, and a collar abutted against the ends or the segments opposite to the end panels, said collar having a rectangular channel telescopically fitted to the abutted ends of the segments.

5. An elongated transversely collapsible core having an open end and an opposite closed end comprising two pairs of elongated segments of sheet material arranged in substantially parallel pairs and the segments of each pair being in substantially parallel relation, each segment having a pair of integral elongated longitudinal panels transversely in substantially right angular relation and an end panel normal thereto interconnecting the longitudinal panels in said angular relation, the segments of each pair having adjacent panels arranged in transversely slidable overlapping relation, the corresponding segments of the pairs having adjacent panels arranged in transversely slidable overlapping relation, said end panels slidably overlapping and defining the closed end of the core, locking means accessible through the open end of the core releasably interconnecting the end panels in overlapped relation, and a collar having an opening therein releasably mounted on the opposite end of the segments from the end panels having a rectangular channel telescopically receiving the ends of the longitudinal panels opposite to the end panels constraining the segments to predetermined overlapping rectangular relation.

6. An elongated transversely collapsible core comprising two pairs of elongated segments of sheet material arranged in substantially parallel pairs and each pair consisting of substantially parallel segments, each segment including an elongated face panel longitudinally of the segment, an elongated side panel longitudinally of the segment transversely in substantially right angular relation to the face panel and integral therewith, and an end panel interconnecting corresponding ends of the face panel and the side panel in fixed angular relation, the face panels and the end panels respectively of the segments of each pair of segments slidably overlapping and the side panels and the end panels respectively of corresponding segments of the pairs slidably overlapping, the overlapping portions of the end panels having juxtapositioned elongated openings formed therethrough; screwthreaded means mounted in the openings adapted to clamp their respective end members in adjusted overlapping relation; and a collar having an access opening therein abutted against the ends of the segments opposite to the end panels, said collar having a rectangular channel releasably telescopically receiving the abutted ends of the segments.

LOUIS L. PETERSON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 738,423 Durant Sept. 8, 1903 746,445 Boise Dec. 8, 1903 784,701 Petrie Mar. 14, 1905 838,704 Francisco Dec. 18, 1906 1,244,937 Zagelmeyer Oct. 30, 1917 1,403,363 Webb, Jr Jan. 10, 1922 1,506,475 Burkholder Aug. 26, 1924 1,530,447 Weathers Mar. 17, 1925 1,563,580 May Dec. 1, 1925 

